Modernization of I

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Modernization of IC Systems of NPPs

• Experiences Lessons learned
• KANUPP

Karachi Nuclear Power PlantPAKISTAN
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Introduction
Owner Pakistan Atomic Energy Commission
Prime Contractor Canadian General Electric
Regulatory Authority Pakistan Nuclear
Regulatory Authority Reactor Type
CANDU (PHWR) Electrical Output 137 MW
Thermal Output 432.8 MW Fuel Natural
U Coolant D2O Moderator D2O Fuel Channels 208
KARACHI NUCLEAR POWER PLANT
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Introduction

• Location Paradise Point on the
• Arabian Sea Coast, Karachi
• Type of Reactor Single CANDU PHWR
• Total gross capacity 137,000 kW
• Civil construction 1965-1971
• First Criticality August 1, 1971
• Full Power achieved on October 4, 1972
• Formally inaugurated on November 28, 1972
• No radiological incident occurred during life
  time.
• IAEA missions and WANO Peer Reviews did not find
  any significant deficiency resulting in
  compromise to plant safety

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Modernization of KANUPP IC

• AIMS OF MODERNIZATION OF ICModernization of
  KANUPP Computers, Control Instrumentation was
  aimed at providing long term solutions to address
  the aging, obsolescence of equipment and the life
  extension of the plant beyond its designed life

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Modernization of KANUPP IC

• Upgradation replacement has been done in the
  following areas
• Pneumatic discrete electronics based
  instrumentation used for indication, recording
  control of process parameters e.g. pressure,
  level, flow, temperature.
• Pneumatic discrete electronics based
  instrumentation used for safety related
  functions.
• Digital computers used for reactor control,
  alarm, annunciation logging and other Control
  monitoring functions.

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Modernization of KANUPP IC

• Process Control Computers have now been replaced
  by new IC Systems based on Programmable Control
  Systems. Following distinct Plant Functions are
  now being performed by these systems
• Reactor Power Regulation
• Fuel Channel Temperature Monitoring
• Bearing Temperature Monitoring of Pumps Motors
• Failed Fuel Activity Monitoring
• Alarms Annunciation

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Modernization of KANUPP IC

• CI LoopsThe selected IC loops of the plant
  have been successfully replaced
• Measurement 54/238
• Closed Control 37/49
• Reactor Protection 49/49
• Reactor Safeguard 15/15

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Modernization of KANUPP IC

• Planning and Pre-project phase
• Scope of Backfitting
• Feasibility studies
• Joint engineering studies
• Manpower development

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Modernization of KANUPP IC

• Project Implementation
• Preparation of specifications
• Bid preparation/ Evaluation
• Contract Negotiation
• Project Engineering
• Procurement of equipment

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Modernization of KANUPP IC

• InstallationSince the plant had to operate, the
  installation work was carried out in phases.The
  installation of electronic rooms, UPS and cable
  trays were carried out during plant operation.
  Whereas the installation of field and control
  room equipment were carried out during shutdown
  periods. And switch over to new system achieved
  during two six months long shutdowns. Due to this
  the overall installation time was longer than it
  should be but on a running plant it was
  unavoidable.

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Modernization of KANUPP IC

• Pre-commissioningPrior to pre-commissioning
  tests Installation verification were done to
  check for proper installation as per design
  documents and remove any deficiencyFollowing
  pre-commissioning tests were performed by the
  dedicated group as per written approved
  procedures -Testing of valves positions as per
  fail safe criteria on Loss of Air and Power
  positions
• -Loop checks from sensor to final control
  element -Testing of alarms and
  permissive -Signal communication to Process
  Monitoring -Testing of Application Programs

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Modernization of KANUPP IC

• CommissioningCommissioning of the new IC loops
  was planned in two stages
• Partial commissioning For the loops whose
  process was not available, the loops were tested
  by simulated process signals and testing of all
  the functions were performed.
• Final commissioning During start up of plant
  final commissioning of all the loops was
  performed including all the comprehensive and
  routine tests.

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Measurement Loop Architecture
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Reactor Protection Loop Architecture
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Safeguard Loop Architecture
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Redundant Control Loop Architecture
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Normal-Help Control Loop Architecture
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OLD AND NEW CONTROL STATION
20mA
DEV
PROCESS WATER PUMP DIFFERENTIAL
20

10
C.D.
0
100
HAND
AUTO
50

10
100
50
N2


D I F F
0
20
-
VALVE
4mA
80
40
-
T
U
1.5
GOSSEN
2
-
60
30
20mA
20mA

PSID
CV1
S.P.
50
40
20
100
40
80
TRANSFER
30
60
SP
M.V.
CV2
50
20
10
100
40
SET POINT
40
20
30
50
20
0
0
20
10
HAND
10
N3
N1
0
0
0
0
4mA
4mA
-
T
U
U
T
-
GOSSEN
1.5
1.5
GOSSEN
2
2
-
-
Bailey
PW6Q-CS
PW PUMP P
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Modernization of KANUPP IC
A view of Installation in Electronic Room
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Modernization of KANUPP IC
Distributed Control Systems
Installation and signal continuity verification
phase of Electronic and marshaling cubicles.
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Modernization of KANUPP IC
Test / Calibration of Process CI
Maintainers Training for maintenance, testing
and calibration of new CI Devices before
installation.
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Modernization of KANUPP IC
OLD CONSOLE WITHOUT VDU
NEW REACTOR POWER REGULATION CONSOLE
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Modernization of KANUPP IC
KANUPP CONTROL ROOM PANEL ENGINEERING GIVE AN
EASE TO OPERATORS
OLD PANEL WITH PNEUMATIC CONTROLLERS
NEW PANEL WITH PLC CONTROLLERS
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Modernization of KANUPP IC
OLD LINE PRINTERS
MAN-MACHINE INTERFACE OF NEW IC SYSTEMS
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KANUPP CONTROL ROOM
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NEW FEATURES AND ENHACEMENTS

• Automatic fault detection for measurements and
  the processing hardware
• Distributed Control System with full function
  backup controllers provides improved control of
  the process and increased reliability and
  availability
• Valve position measurement provides indication of
  actual valve position in the field as well as
  automatic detection of valve position discrepancy
  if it arises which is annunciated for corrective
  action initiation well in time

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NEW FEATURES AND ENHACEMENTS

• PC based Man-Machine Interface providing ease of
  operation and effective navigation using
  Trackball, Mouse, Keyboard
• Easy Access to Plant Parameters required for
  Plant Operation in different modes and effective
  handling of Transients
• Data Recording and Display for Analysis of Plant
  Behavior
• Alarms Management Functions for identification
  and diagnosis of Plant Transients

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Operator Feed Back

• The man-machine interface has been improved
  significantly and the operator now feel very easy
  to monitor and control the plant status
• Annunciation for various faults has enabled the
  operator to take corrective action well in time
• The performance of the plant has greatly improved
  after replacement of computers and ICs and the
  no. of trips has been reduced significantly

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LESSONS LEARNED

• Modernization of IC enhances the performance of
  the system and provide ease of maintenance as the
  vendor support and spares are available easily,
  so it be planned in a plant life as soon as the
  technology advancement makes it necessary.
  Although cost factors involve at first stage but
  pays in the long run after the modernization

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LESSONS LEARNED

• The modernization of IC also provides
  opportunity to enhance the previous design,
  enables to remove the short comings of previous
  design and provides an opportunity to improve the
  man machine interface as per operators feed back
  of the particular plant

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LESSONS LEARNED

• Modernization of IC provides the opportunities
  to train manpower for new technologies, modern
  equipment, advance tools and testing equipment,
  modern working methodologies

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THANK YOU